Fabric, protective garments made therefrom, and methods of making

ABSTRACT

Disclosed herein are protective garments comprising an inner surface or portion of an inner surface with both absorbent and stain resistant properties while maintaining the soft feel, breathability and aesthetic properties associated with traditional “non protective” intimate apparel. The fabrics and methods of constructing the garments are also disclosed herein.

RELATED CASES

Priority is hereby claimed to U.S. Provisional Patent Application No.61/164,000, filed on Mar. 27, 2009, which is incorporated herein byreference in its entirety.

TECHNICAL FIELD

The present disclosure is related to functional fabrics, protectivegarments made therefrom, particularly protective undergarments, andmethods of making the foregoing.

BACKGROUND

Many varieties of feminine sanitary products have been commercialized,and are designed to absorb bodily discharges. For instance, sanitarynapkins and tampons exist in many designs and iterations with slightlyvarying functions to absorb menstrual fluid. However, many products arenot fully adequate, allowing menstrual discharges to leak onto women'sinner and outer apparel, often leaving stubborn stains on the apparel,especially if allowed to dry before washing. Some women immediately maythrow away stained undergarments, but many attempt to remove the stainsusing a variety of cleansers and techniques. Without thorough cleansing,stains may become permanent, which may be a source of embarrassment ifothers see the stains. When a leak extends to a woman's outerwear, itmay require the involvement of a cleaning service, which is even moreembarrassing.

Although leaks may occur at any time, women tend to experience them moreoften in the following two instances: on the first day of the menstrualcycle, when not yet wearing appropriate sanitary products, and whenlying down, usually during sleep. However, various vaginal dischargeswith the potential to stain garments occur throughout the month.

Some undergarments have been designed to solve the issue of menstrualleaks and staining However, such products are either not adequatelyprotective and have no barrier properties (offering only absorbentcharacteristics), or alternatively, they are constructed with barrierfabrics that are aesthetically unpleasing and uncomfortable.

Diapers and adult incontinence products are generally absorbent on theinside, but because they need to absorb very large amounts of liquid,they use thick pads where aesthetics are completely different from theconstructions of the present concept. Because the fluid levels arehighly varied and quite large in these products, they also use completefilm barriers that are generally not air permeable.

While these garments have some functionality, none of them are suitablefor use as an undergarment for daily use.

There is a need for functional fabric and garments made therefrom thatabsorb fluid, prevent the transmission of fluid to outerwear, do notpermanently stain, and additionally are sufficiently attractive andcomfortable to wear on a daily basis in place of non-protectiveundergarments.

SUMMARY

The present disclosure is directed, in one embodiment, to a garmentportion, comprising at least one absorbent layer comprising abody-contacting surface, and an absorbent capacity of at least about 300g/m2; and at least one repellent layer disposed adjacent to the at leastone absorbent layer and comprising an outer surface disposed oppositethe body-contacting surface.

In another embodiment, the present disclosure is directed to a garmentportion comprising at least one absorbent layer comprising abody-contacting surface; and at least one repellent layer disposedadjacent to the at least one absorbent layer and comprising an outersurface disposed opposite the body-contacting surface; wherein thegarment portion comprises a combined weight of less than about 20oz/yd2.

In another embodiment, the present disclosure is directed to a garmentportion comprising at least one absorbent layer comprising abody-contacting surface; and at least one repellent layer disposedadjacent to the at least one absorbent layer and comprising an outersurface disposed opposite the body-contacting surface; wherein thegarment portion comprises a combined absorbent capacity of at leastabout 40 ml.

Any one of the foregoing garment portions may be transmissive to airand/or transmissive to moisture vapor. One or both surfaces of thelayers can comprise a napped, sueded or texturized surface, adapted toabsorb fluid and to wick the absorbed fluid through to the adjacentlayer.

The at least one absorbent layer and the at least one repellent layercan be a polymeric material or a microfiber material, and combinationsthereof. The polymeric material can comprise polyolefins, polyamides,and combinations thereof.

The at least one repellent layer can comprise a water repellant finish,which may be a film having a thickness of less than about 10 microns(μm). In some embodiments, the film may be driven into the fabric byheat and pressure. The at least one repellent layer is a meltblownmaterial such as a stretchable polymer such as polyurethane orco-polyether-ester, or a microfiber layer. The at least one repellentlayer can comprise a fabric which has been coated or saturated with asilicone or polyurethane or other elastic water repellent polymer.

In some embodiments, the at least one absorbent layer and at least onerepellent layer may be bonded together, and the bonding may be at anedge of each layer.

Another aspect of the disclosure is an undergarment comprising one ofthe foregoing garment portions, which is a gusset portion of theundergarment. The gusset can comprise a front edge, a side, a back edgeand opposing side edges, and the front and back edges are attached to afront and a back of the undergarment at a front seam and a back seam.One or more of the front and back seams comprise an inverted triangularshape, and/or one or more of the front and back seams extend to an upperedge of the undergarment. In some embodiments, one or more of the frontand back seams can comprise a hydrophobic coating. In other embodiments,one or more of the opposing edges can comprise a hydrophobic coating. Inyet other embodiments, one or more of the front and back seams and oneor more of the opposing edges can comprise a hydrophobic coating.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the figures, which are exemplary embodiments, andwherein like elements are numbered alike:

FIG. 1 shows front, back, interior and exterior views of one exemplarygarment according to the present disclosure;

FIG. 2 shows front, back, interior and exterior views of anotherexemplary garment according to the present disclosure;

FIG. 3 shows front, back, interior and exterior views of anotherexemplary garment according to the present disclosure;

FIG. 4 shows front, back, interior and exterior views of anotherexemplary garment according to the present disclosure;

FIG. 5 shows a cross-sectional view of one exemplary multi-layer fabricaccording to the present disclosure;

FIG. 6 shows a cross-sectional view of an other exemplary multi-layerfabric according to the present disclosure;

FIG. 7 shows a cross-sectional view of another exemplary dual-layerfabric according to the present disclosure;

FIG. 8 is a table (Table A) listing the characteristics of varioushydrophobic and hydrophilic fabrics;

FIG. 9 is a table (Table B) summarizing the qualitative results ofpanties constructed using various combinations of fabrics listed in FIG.9; and

FIG. 10 is a table (Table C) summarizing the absorbent capacity ofselected panties from FIG. 10.

DETAILED DESCRIPTION

The present disclosure is directed to protective garments that provideleak resistance, fluid absorbance and fluid barrier characteristics. Insome instances, the garments also may provide stain resistance and/orstain-releasing characteristics. The protective garments are stretchyand breathable, have a non-film like drape, and an attractive look andfeel. Exemplary protective garments according to the present disclosureare protective undergarments, particularly women's protectiveundergarments, which can be made aesthetically attractive, similar tonon-protective women's undergarments, thereby offering women the abilityto wear the protective undergarments without discomfort orembarrassment.

The undergarments can comprise at least one layer of a fabric that ishydrophilic, or treated to be hydrophilic, disposed adjacent to at leastone layer of fabric that is hydrophobic or treated to by hydrophobic.Alternatively, the undergarments can comprise a single layer of fabricwith a first surface that is hydrophilic or treated to be hydrophilic,and second surface that is hydrophobic or treated to be hydrophobic,opposite the hydrophilic surface. The present garments are constructedto absorb and/or contain the volume of fluid from a woman's menstrualcycle, which may be in the range of 5-30 milliliters and varies, ofcourse, depending on many factors.

The present garment construction does not require a film or coating,which tends to be uncomfortable or undesirable for the reasons notedabove. The foregoing characteristics are accomplished with the use ofunique functional fabrics and garment constructions. The presentundergarments provide effective leak resistance against and/or act as afluid barrier against blood spills, while remaining breathable andstretchable.

In certain embodiments, the fabrics may be stretchable knit fabrics,which provide leak resistance and/or act as a fluid barrier, in theabsence of a film or coating. The use of such fabrics for leakresistance and/or as a fluid barrier is unique, with or without the useof elastane (e.g., Lycra) in the fabric.

FIG. 1 shows an exemplary embodiment of an undergarment 10 according tothe present disclosure, which will be referred to hereinafter for easeof illustration as a panty 10. Panty 10 comprises a body portion 12 anda gusset region 14. Body portion 12 comprises an upper edge 12 adefining a waistband, and two leg openings 12 c. Gusset region 14comprises front and back edges 14 a,b, and opposing side edges 14 c,d.Gusset region 14 is attached to the body portion 12 at the front andback edges 14 a,b, defining a front seam 16 f and a back seam 16 b.Gusset region 14 comprises a functional material 100 according to thepresent disclosure, as will be described in further detail below.

Optionally, the shape and position of the front and back seams 16 f,bmay be varied relative to the upper edge 12 a, to accommodate stains aresometimes found in the front and/or back areas of the underwear,especially at the edge of the front and back of sanitary napkins. Forexample, FIG. 2 shows another exemplary embodiment of an undergarment 20in which the front and back seams 16 f,b comprise the shape of aninverted triangular, which assists in preventing leaks, spotting, andstains on the front and back of the underwear.

Also optionally, gusset 12 can extend to the upper edge 12 a of thepanty, as shown in FIG. 3. in which the gusset 14 extends up to and isco-terminus with the upper edge 12 a of the panty. Alternatively or inaddition to, the panty can comprise one piece of fabric continuing tothe aforementioned front seam, as shown in FIG. 4.

FIG. 4 shows another exemplary embodiment of an undergarment 40according to the present disclosure. To maximize the underwear'sfunction and aesthetics, seams, like those that would be created byunderwear designs shown above, may be avoided by constructing the pantyso that the entire front to back may be made of the aforementionedfunctional fabrics. Such a construction involves attaching the gusset 14at the front and back edges 14 a,b to a band 18 of fabric that has adifferent composition than the main body 12 of the panty. As shown, suchfabrics may include lace, silk, chiffon, cotton, or any fabric that mayor may not be treated to have functional properties, but moreimportantly prevents visible panty lines around the waist area. In thepresent embodiment, the underwear may or may not include a gusset.

In any and all of the foregoing embodiments, the gusset 14 of theundergarment may be composed of one or more separate pieces of fabricthat are not bound together. This design allows for the wings of asanitary pad to be inserted between the separate layers of fabric in adiscreet and comfortable way.

One iteration is designed similar to regular non-functional underwear,however, the entire garment may be made of functional fabric (excludingdecorative embellishments), with iterations described above, or with noseams such that the entire underwear, excluding the band, is made of onesingle piece of fabric. By constructing the entire lower side of theunderwear with special fabrics, the underwear can protect the wearer ofthis garment from unwanted stains and leaks without compromising style.However, the upper area of the garment does not need to have suchspecial functionalities, thus it may be made out of any fabric to lowerthe cost of the garment. This is true unless the fabric on the lowerpart of the garment has immense wicking capabilities that result in thetransfer of fluids to the top band of the garment. Then, the band may betreated with a hydrophobic finish. Even so, this may decrease theoverall cost of the garment as compared to the entire underwearconstructed with the invented combination of fabrics, and this mayincrease the aesthetics and functionalities of the underwear.

Any and all of the materials, fabrics, layers and techniques describedabove may be combined, or may be used individually.

The present disclosure provides fabrics that may be used in theforegoing and other garments. “Fabric,” as used herein, refers to asingle or multiple layers of fabrics. The present fabric and garmentconstructions provide unique advantages of stain resistance, fluidretention, fluid absorbency, and garment aesthetics (look, feel,softness and stretch) that are comparable to those of standard(non-protective) undergarments. The garments are not intended to replacefeminine hygiene products such as sanitary napkins and tampons, but tocomplement such products during a woman's menstruation.

The fabric may have a total weight range of less than 7 oz/sq yard up toabout 14.6 oz/sq². The fabric may comprise a top fabric layer or layerswith a total absorbent capacity of at least about 300 g/m² as determinedusing the Eulie Dip Test, more particularly at least about 800 g/m²,more particularly at least about 1300 g/m².

It is desirable for the inner layer to absorb fairly rapidly to avoidspills, and thus the inner layer should have an absorbency percentage ofat least 10% as determined in ASTM D4772. It is important that thefabric actually absorb into the fibers rather than simply hold liquidlike a sponge.

FIG. 5 shows one exemplary multi-layer fabric section 50 that can beused in any garment, including any of the foregoing embodiments. Fabricsection 50 comprises four layers: a first, body contacting, layer 100; asecond, absorbent layer 200 disposed adjacent to the body-contactinglayer 100; a third, fluid-resistant or fluid-proof barrier layer 300disposed adjacent to the absorbent layer 200, opposite layer 100; and,an optional fabric layer 400 that may be included for, among otherthings, aesthetic reasons.

Layer 100 may be any material that is capable of allowing thetransmission of fluid to the absorbing layer 200, and that remainsrelatively dry even when fluids penetrate its surface. The dryness oflayer 100 may be achieved through several methods. For example, whenfluid is released on a point source of the inner surface(body-contacting surface) of layer 100, the fabric can distribute thefluid by wicking it across a greater surface area. Alternatively, layer100 may be non-absorbent, such that fluid is transferred to layer 200,allowing layer 100 to remain free of fluid and, consequently, stains.The stains in layer 200 then become opaque from the perspective of thewearer.

Suitable materials for the layer 100 include, but are not limited to,fabrics made from the following naturally stain resisting fibers:polyolefin, polyamide, polyester, and combinations thereof. For ease ofdiscussion, the term “stain-releasing,” will be used herein to mean bothstain-resistant materials and stain-releasing materials, including thosethat have been treated to be stain-resistant or stain-releasing.Alternatively, the layer 100 can comprise any suitable fabric that hasbeen treated with a stain releasing or resisting finish (such as theDarlington finishes shown in Table A). Layer 100 also can comprise aninherently stain-releasing material such as microfiber or a microfiberblend comprising different materials that can be treated to have evengreater stain-releasing capabilities.

Alternatively, or in addition to the foregoing, layer 100 may have arelatively dark color that can assist in masking stains.

The absorbent layer 200 can comprise any material capable of absorbingfluid, and of releasing the absorbed fluid under certain conditions (forexample, during a laundry cycle). The absorbent layer can comprise anabsorbency of greater than about 300 grams/per square meter (“gm/m²”);more particularly greater than about 800 gm/m², and more particularlystill greater than about 1300 gm/m².

Suitable materials for the absorbent layer 200 include, but are notlimited to, woven or nonwoven microfiber or plastic knits; fabricsformed using hydrophilic fibers, absorbent or superabsorbent foams,fibers or powders.

Alternatively, any knit, absorbent knit, woven, nonwoven or polymericmaterial that has reservoir properties due to air gaps or voids can beused as the absorbent layer 200. Examples of such materials include, butare not limited to, double needlebar knit fabrics, foams, nonwovens, andthe like.

In some embodiments, the absorbent layer 200 can comprise a knittedfabric that has been treated to have hydrophilic properties.Additionally, the yarn from with the knitted fabric is made can betreated to be hydrophilic, prior to knitting. In some embodiments, theyarn and the knitted fabric can both be treated to be hydrophilic.

Alternatively, it is possible that the absorbent layer could beremovable and possibly disposable, eliminating the requirement for stainresistance. Such as disposable layer may comprise, for example, a thinabsorbent or superabsorbent foam, fabric, nonwoven or composite.

Alternatively, the absorbent layer 200 can be covered with an aestheticnon-staining inner layer 100 that can mask some level of staining, whichwould then remain invisible to the consumer.

The barrier layer 300 can comprise any material or combinations ofmaterials that prevent or minimize the transmission of fluid through thebarrier layer, and that do not adversely affect the feel and/or hand ofthe garment.

While many materials may be used in combination for the barrier layer,we devised a unique test for measuring elongation and have found thatthe use of fabrics or nonwovens elongations comparable to the Darlingtonfabrics listed in Table A to be effective.

By having an inner layer capable of absorbing the specified quantity offluids, the hydrostatic pressure resistance of the barrier layer can belimited, which allows more latitude with creating desirable aesthetics.

Some suitable materials for the barrier layer 300 include, but are notlimited to, a fabric laminated to a polymer film. The polymer film cancomprise a thickness of less than or equal to about 15 microns, moreparticularly less than or equal to about 10 microns, and moreparticularly still less than or equal to about 5 microns. Suitablematerials for the polymer film include, but are not limited to,copolyether-esters, hytrels, nylons, polyolefins, and other soft elasticTPE could be used if they have sufficient softness and pliability to beused in an undergarment. The polymer film may be laminated in a 2-ply or3-ply configuration, or may be free-hanging and sewn between otherlayers (such as an absorbent layer and an aesthetic layer). One suitablepolymer material is a highly moisture transmittable monolithicpolyurethane film sold by Omniflex Inc. of Greenfield, Mass. under thename TX1540.

Other suitable materials for the barrier layer 300 include, but are notlimited to, a 2-ply laminate polymer film protected by another layer,which is not bonded to the film, as this allows for a softer feel in thefinished garment. The film/composite may also be treated with ahydrophobic (water-repellent) treatment to enhance the barrierproperties without negatively impacting the hand. Also, in still anotherembodiment, the barrier film or composite can be pressed with heatand/or pressure into the surrounding layers to enhance feel, or isstretched. This heat/pressure or stretching treatment also has theadvantage of creating small fissures to enhance breathability.

Other suitable materials for barrier layer 300 can comprise ahydrophobic fabric, which may be inherently hydrophobic, or it may betreated to make it hydrophobic. Suitable fabrics for treating with suchhydrophobic coatings include, but are not limited to, relatively tightlyknitted, nonwoven or woven fabrics. Suitable hydrophobic materials fortreating the fabric include, but are not limited to, polymers such assilicone, polyurethane and combinations thereof. In many cases it isdesirable to use elastic polymers for this purpose, such as Lycra andblends thereof. It may be desirable for the hydrophobic treated knitted,nonwoven or woven material to contain microfibers, as this creates amore tortuous path for any fluid to penetrate.

If the material used to form the barrier layer is nonwoven, the use of ameltblown nonwoven may be desirable since it also creates a tortuouspath for fluids. Multiple nonwoven, knits or wovens may also be combinedin any number of layers, and various or all layers may be treated withhydrophobic treatment or made of naturally hydrophobic material(s). Incases where these treated (non-film) materials are used in the conceptthere may be the advantage of greater breathability than may be achievedwith a film barrier. One exemplary barrier layer is an elastic meltblownnonwoven material made from a co polyether-ester polymer similar to theproduct that was once sold by Kimberly Clarke under the brand nameDemique.

Other suitable barrier layers 300 can comprise a microporous polymerfilm. Suitable microporous polymer films include, but are not limitedto, urethane films, PTFE films, polyolefin films, and combinationsthereof. One microporous urethane film is sold by Porvair of England.Suitable microporous PTFE films are available under the product nameGoretex. The foregoing microporous films can be used in any combinationof layers, either laminated or unlaminated, and can be treated with ahydrophobic water repellent treatment, or filled with a substance suchas oil, to keep the pores from becoming contaminated.

Any type of material can be used as the optional aesthetic layer 400.Examples of suitable materials for layer 400 include, but are notlimited to, lace, silk, chiffon, cotton, polyester, nylon, LYCRA®, andthe like, and blends and combinations thereof. If desired, the fabriccan be colored, printed, etc., and may be treated to have any of thefunctional properties described herein.

FIG. 6 shows another exemplary multi-layer fabric section 60 that can beused in the present garments, comprising three layers: a first, bodycontacting and absorbent layer 500; a second, fluid-resistant orfluid-proof barrier layer disposed adjacent to the absorbent layer,opposite layer 300; and, optional fabric layer 400. Suitable materialsfor layers 300 and 400 are the same as those described above.

Suitable materials for layer 500 include any material that is bothstain-resistant and that is capable of absorbing fluid and, undercertain conditions, releasing the fluid. Examples of suitable materialsfor layer 500 include materials discussed above with respect to layer200, one surface (the body-contacting surface) of which has been treatedwith a material that imparts stain resistance. An example of such atreatment would be the Darlington treatments listed in Table A, butcould also be any similar treatment.

FIG. 7 shows another exemplary dual-layer fabric section 70 that can beused in the present garments, comprising a first, body contacting layer600 and an optional fabric layer 400. The functional features of thepresent concept may all be combined in a single layer of fabric 600 thatcombines fluid absorption and barrier characteristics and, in someinstances, stain-releasing characteristics. Such a fabric may beconstructed of one or more fibers with one or more of the foregoingcharacteristics, to combine the characteristics of the different fibersto achieve the desired undergarment properties. In some cases, it may bedesirable for a single fabric layer to have the opposing surfaces of thefabric faced with different types of fibers, each having differentcharacteristics (e.g., one fiber that is hydrophobic and absorbent, onefiber that is hydrophilic).

For example, layer 600 can comprise a single layer of fabric comprisinga first surface that is stain resistant (naturally, or as a result ofbeing treated with a stain resistant treatment, as described above) andabsorbent, and a second surface that is hydrophobic. The first surfacecan be capable of absorbing an amount of fluid between about 0.1milliliters (“ml”) and about 50 ml of fluid within as little as 95 cm²up to the entire surface area of the undergarment, and more particularlybetween about 3 ml and about 15 ml of fluid. The second, oppositesurface of the layer can be treated to be hydrophobic (as describedabove) and to prevent or minimize the transmission of the absorbedfluids. The second surface may be treated with traditional DWRtreatments (such as Zepel or other treatments) and/or it may besaturated or impregnated with a hydrophobic polymer (such as silicone orurethane). The hydrophobic polymer fills the gaps in the fabric, and maybe applied by dip and squeeze, knife over roll, spray, gravure, or othermethods. The fabric used may be, for example, a knit and with thestretch characteristics described above. The fabric may also include theuse of microfiber.

Improved performance may be obtained by bonding the seams togetherwithout stitching using tape or adhesive seams, or using sealants overthe stitched seams. Suitable materials include elastic polymer sealantsand adhesives. Seams can be sealed with seam tape such as WorthenIndustries Tape 375-4, using a Pfaff seam sealing machine to eliminatesewing the edges of the gusset together or to the body of the garment.Non-wicking thread may also be used to minimize or eliminate blood fromwicking along the thread in stitched seams.

In any and all of the embodiments disclosed herein, two or more oflayers 100 through and including 600 may be attached at least partiallyto each other using a variety of techniques, in order to reduce thenumber of layers in the garments. For example, the layers may belaminated to form a single, composite layer, or they may be attached bysewing at various attachment points, so that the separate layers remaindetached in between the seams.

Also, any or all of the materials and/or material surfaces in theundergarments can comprise an active agent, such as an antimicrobial orantifungal material. Example of suitable active agents include, but arenot limited to, ionic silver, copper, zinc, nanoparticles thereof, andcombinations thereof (which act as a natural antimicrobials). The use ofnanoparticles does not compromise the aesthetics of the garments, whichis important for undergarments. The active agents can be added to anylayer of fabric or film or in fact into the adhesive if one is used forbonding. The addition of phase-change microspheres may also be used toadd a temperature-regulating feature.

The foregoing fabrics and composites facilitate the construction of manygarments, particularly aesthetically pleasing and protective women'sundergarments. The undergarment designs may be slightly different fromnon-protective undergarments to aid in leak and stain prevention, whilesimultaneously being aesthetically pleasing. Accordingly, the foregoingmaterials and methods of construction may be applied to styles thatcharacterize regular non-protective undergarments, such as briefs,thongs, boy shorts, and the like. Existing “period” underwear is eitherdesigned such that the protective gusset is of regular size or theprotective gusset extends to the back waistband in a fashion that isunappealing. The present concept provides designs are functional inpreventing leaks and stains but are also aesthetically pleasing.

The functional fabrics discussed above have many other uses includingbut not limited to regular women's and men's apparel, men's functionalapparel, industrial fabrics, sporting apparel, and protective apparel.The garment and fabric constructions described herein are designed foruse in protective intimate apparel to absorb and/or contain bodilydischarges and to resist staining and/or release staining whenlaundered, while not negatively impacting the look, feel andbreathability for use in intimate apparel and other clothing. Thegarments and construction methods described herein may be used for avariety of garments including but not limited to underwear, bras,bathing suits, and outerwear.

While one use for this unique combination of materials is for protectivepanties during menstruation, the present concept may also be used forunderwear and outerwear preventing leaks and stains during pregnancy,post-partum, menopause, and post-menopause. The capabilities may be usedseparately or combined in panties, bras, outer clothing, bathing suits,and the like. The potential wicking capabilities may be usedspecifically in, but not limited to, outerwear and sleepwear formenopausal women. In addition, pregnant and post-partum women oftenexperience unexpected lactation, causing uncomfortable and embarrassingstains and/or leaks on bras and/or outer garments. The use of thisconcept for construction of nursing bras can alleviate thisinconvenience. Pregnant and post-partum women also experience heavyvaginal bleeding during pregnancy and after giving birth, creating astrong need for stain releasing and leak proof products. In addition,pre-teen girls often experience anxiety about menstruating for the firsttime. The present materials and construction techniques provide garmentsthat would allow them to feel at ease knowing they are protected frompotential leaks or stains.

Working Examples Fabric Testing

Two categories of fabrics were tested for use in the present garments:absorbent (hydrophilic) fabrics and repellent (hydrophobic) fabrics.Table A summarizes the fabric and yarn type and treatment, if any, aswell as the manufacturer's reported fabric weight, the total waterabsorbency (as determined by the “Eulie Dip Test,” discussed below), andthe measured Absorbent capacity (as determined by the “Eulie CapacityTest, discussed below). Throughout the Tables, the absorbent layerfabrics are referred to by a letter designation A, B or C, and therepellent layer fabrics are referred to by a numeric designation 3, 4 or5.

Eulie Dip Test

As noted above, the total water absorbency of each fabric was testedusing the Eulie Dip Test, which involves measuring, cutting and weighinga five inch by five inch (5″×5″) dry piece of fabric. The fabric piecewas then fully submerged in water for 15 seconds, after which it wasremoved from the water while holding only the upper corners. The excesswater was allowed to drain from the fabric piece for twenty-five (25)seconds, after which the fabric piece was weighed a second time. Thetotal water absorbency was calculated by subtracting the dry fabricweight from the wet fabric weight, as shown in Table A.

Eulie Capacity Test

Also as noted above, the absorbent capacity of each fabric was testedusing the Eulie Capacity Test, which involves which involves measuring,cutting and weighing a five inch by five inch (5″×5″) dry piece offabric. The fabric section was disposed on an angled surface of five (5)degrees, and the tip of a titration tube was disposed one (1) centimeter(cm) above the fabric surface, four (4) cm from the upper edge of thefabric section, centered on both sides of the fabric section. Fluid(water containing green food coloring) was dispensed from the titrationtube at a flow rate of approximately 20 milliliters/minute. Fluid flowwas discontinued when water ran off the edge of the fabric section, orwhen water reached all four corners of the fabric section. The absorbentcapacity listed in Table A represents the total volume of waterdispensed from the titration tube.

Functional Trials

The fabrics listed in Table A were used to construct panties forFunctional Trials by women during their menstrual cycle. The pantieswere constructed by forming gussets with various combinations of thefabrics listed in Table A, which then were stitched over the gussetregion of various branded panties (e.g., Hanes®, etc.).

The panties were forwarded to volunteer testers. The testers wore thepanties while menstruating, and recorded the amount of time that thepanties were worn and the amount of time between wearing and washing thepanties. After washing, a record of any remaining stains was recorded bythe testers, along with qualitative remarks about the comfort andeffectiveness of the panties.

There was an aesthetic trade off when the gusset became too bulky orthick due to multiple layers. Therefore, it is desirable to provide themaximum amount of absorbent capacity per thickness or weight of theabsorbent layers. Some of the best performing composites from thefunctional trial included 3 layers of thin absorbent layer “A” (Example1), but a single absorbent layer C (Example 6) also appears to performwell.

Fabric A appeared to absorb liquids initially faster than Fabric B,resulting in fewer instances of “puddling” or “pooling” directly abovethe repellent fabric.

Fabric 3 appears to have provided better leakage protection than Fabric4, likely due to the slightly higher weight of Fabric 3.

The results of the panty tests showed that the performance was dependentupon a variety of factors including the hand, weight, absorbency andperceived thickness of the gusset.

Throughout the application, it should be noted that the terms “first,”“second,” and the like herein do not denote any order or importance, butrather are used to distinguish one element from another, and the terms“a” and “an” herein do not denote a limitation of quantity, but ratherdenote the presence of at least one of the referenced items. Similarly,it is noted that the terms “bottom” and “top” are used herein, unlessotherwise noted, merely for convenience of description, and are notlimited to any one position or spatial orientation. In addition, themodifier “about” used in connection with a quantity is inclusive of thestated value and has the meaning dictated by the context (e.g., includesthe degree of error associated with measurement of the particularquantity).

Compounds are described using standard nomenclature. For example, anyposition not substituted by an indicated group is understood to have itsvalency filled by a bond as indicated, or a hydrogen atom A dash (“-”)that is not between two letters or symbols is used to indicate a pointof attachment for a substituent. For example, —CHO is attached throughcarbon of the carbonyl group. Unless defined otherwise herein, allpercentages herein mean weight percent (“wt. %”). Furthermore, allranges disclosed herein are inclusive and combinable (e.g., ranges of“up to about 25 weight percent (wt. %), with about 5 wt. % to about 20wt. % desired, and about 10 wt. % to about 15 wt. % more desired,” areinclusive of the endpoints and all intermediate values of the ranges,e.g., “about 5 wt. % to about 25 wt. %, about 5 wt. % to about 15 wt.%”, etc.). The notation “+/−10% means that the indicated measurement maybe from an amount that is minus 10% to an amount that is plus 10% of thestated value. Finally, unless defined otherwise, technical andscientific terms used herein have the same meaning as is commonlyunderstood by one of skill in the art to which this disclosure belongs.

While the disclosure has been described with reference to an exemplaryembodiment, it should be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the disclosure. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the disclosure without departing fromthe essential scope thereof. Therefore, it is intended that thedisclosure not be limited to the particular embodiment disclosed as thebest mode contemplated for carrying out this disclosure, but that thedisclosure will include all embodiments falling within the scope of theappended Claims.

1. A garment portion, comprising: at least one absorbent layercomprising a body-contacting surface, and an absorbent capacity of atleast about 300 g/m²; and at least one repellent layer disposed adjacentto the at least one absorbent layer and comprising an outer surfacedisposed opposite the body-contacting surface.
 2. The garment portion ofclaim 1, wherein one or more of the at least one absorbent layer and theat least one repellent layer is a knit fabric.
 3. The garment portion ofclaim 1, wherein one or both surfaces of the at least one absorbentlayer comprises a napped, sueded or texturized surface.
 4. The garmentportion of claim 1, wherein one or both surfaces of the at least onerepellent layer comprises a napped, sueded or texturized surface.
 5. Thegarment portion of claim 1, wherein the at least one absorbent layercomprises a second layer adjacent to the body-contacting layer, whereinthe body-contacting layer is adapted to absorb fluid and to wick theabsorbed fluid through to the adjacent layer.
 6. The garment portion ofclaim 1, wherein the at least one repellent layer comprises a waterrepellant finish.
 7. The garment portion of claim 1, wherein the atleast one repellent layer comprises a fabric which has been coated orsaturated with an elastic water repellent polymer.
 8. The garmentportion of claim 1, wherein the at least one absorbent layer and atleast one repellent layer are bonded together.
 9. The garment portion ofclaim 8, wherein the at least one absorbent layer and at least onerepellent layer are bonded together at an edge of each layer.
 10. Thegarment portion of claim 1, comprising a combined weight of less thanabout 20 oz/yd².
 11. The garment portion of claim 1, comprising acombined absorbent capacity of at least about 40 ml.
 12. The garmentportion of claim 1, wherein the garment portion is a gusset portion ofthe undergarment.
 13. The undergarment of claim 12, wherein the gussetcomprise a front edge, a side, a back edge and opposing side edges, andthe front and back edges are attached to a front and a back of theundergarment at a front seam and a back seam.
 14. The undergarment ofclaim 13, wherein one or more of the front and back seams comprise aninverted triangular shape.
 15. The undergarment of claim 13, wherein oneor more of the front and back seams extend to an upper edge of theundergarment.
 16. The undergarment of claim 15, wherein one or more ofthe front and back seams and one or more of the opposing edges comprisesa hydrophobic coating.
 17. A garment portion, comprising: at least oneabsorbent layer comprising a body-contacting surface; and at least onerepellent layer disposed adjacent to the at least one absorbent layerand comprising an outer surface disposed opposite the body-contactingsurface; wherein the garment portion comprises a combined weight of lessthan about 20 oz/yd².
 18. A garment portion, comprising: at least oneabsorbent layer comprising a body-contacting surface; and at least onerepellent layer disposed adjacent to the at least one absorbent layerand comprising an outer surface disposed opposite the body-contactingsurface; wherein the garment portion comprises a combined absorbentcapacity of at least about 40 ml.